Process for preparing a molded article

ABSTRACT

A film is placed over a mold cavity and molten plastic deposited thereon to form a combination of a film with molten plastic thereon. The film-molten plastic combination is then formed in said mold cavity into a molded article in the shape of the mold cavity.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Provisional Application SerialNo. 60/055,652, filed Aug. 14, 1997 for COMPRESSION MOLDED ARTICLE THATMAY BE COLOR COATED, By Emery I. Valyi.

BACKGROUND OF THE INVENTION

In accordance with U.S. Pat. No. 5,401,457 for PROCESS FOR FORMING ACOLOR COATED ARTICLE, By Emery I. Valyi, Patented Mar. 28, 1995, aprocess is provided for forming a color coated article. In accordancewith the '457 patent, a film is placed substantially flat over a moldcavity and deformed by a core mold half and by molten plastic enteringthrough a sprue.

An alternate method consists of thermoforming the film to nestaccurately in the mold cavity, with said operation being carried outindependently of the mold. The formed film insert is then brought to themold and placed into the cavity. This procedure is described by Ch.Fridley, Avery Dennison, in Product Finishing, Apr. 19, 1992, andEuropean Patent 0,442,128 to Beyer, and other publications. The Averyprocedure entails a forming process of the film that is well known andwidely practiced for other uses. It is a low pressure process forshaping the film or sheet, in solid condition, at relatively lowtemperatures. This holds for all of the several variants ofthermoforming, such as vacuum forming, whether the vacuum is to suck thefilm into the cavity, or onto the core, as well as thermoformingfollowed by a sizing operation.

The result of this is a product whose dimensional accuracy and shapeconformance is not within the range of a high pressure forming process,such as injection molding or compression molding. Consequently, thethermoformed preform, while nesting in the mold cavity or slipped overthe core, fails to conform to them fully. Thus, upon injecting orcompressing plastic behind the preform, the preform will deformproducing localized surface imperfections. These imperfections may bedimensionally insignificant but optically discernible and therefore mayprovide a product of insufficient quality for an automotive finish, forexample. In addition, the cost of a separately made film insert isrelatively high, considerable trim scrap is generated, and the handling(transport, destacking, insertion) become expensive.

The procedure of the '457 patent overcomes the above defects; however,it is difficult to control, particularly when molding parts with largesurfaces and sharply varying curvature. The difficulties increase whenthe plastic is pressure molded at high enough temperatures to reduce thefilm strength substantially, as in the case of conventional injectionmolding.

In applying either of the above processes to large, panel-likestructures, it was found, moreover, that the procedure of injectionmolding of the '457 patent and Avery Dennison procedure referred toabove, is difficult to carry out, requiring extremely costly equipment,and prone to produce imperfections at the interface between the filmlayer and the injected plastic.

Accordingly, it is a principal object of the present invention toprovide a process and apparatus which conveniently and expeditiouslyforms a molded article from molten plastic and a film insert, whereinthe film is the outer layer of the molded article and wherein desirablythe film is colored.

It is a further object of the present invention to provide a process andapparatus as aforesaid which overcomes the foregoing defects andprovides a commercially feasible process and apparatus for forming acolor coated article.

It is a still further object of the present invention to provide aprocess and apparatus as aforesaid which is operative under conditionsthat are sufficiently controllable and cost efficient to produce complexparts, particularly those of a size of major body components ofpassenger cars.

Further objects and advantages of the present invention will appearhereinbelow.

SUMMARY OF THE INVENTION

In accordance with the present invention, the foregoing objects andadvantages are readily obtained.

The present invention includes a process for preparing a molded article,which comprises: providing a mold cavity; placing a film or blank overthe mold cavity; depositing molten plastic on said film to form acombination of a film with molten plastic thereon; and subsequentlyforming said film-molten plastic combination in said mold cavity into amolded article having the shape of said mold cavity, wherein the film isan outer layer of the molded article. Desirably, the film is colored andis held over the mold cavity and molten plastic is deposited onto thefilm. Also, preferably the combination is formed into the shape of themold cavity at least in part by a mold core which compresses thecombination and forms the combination into the shape of the mold cavity.Thus, the resultant article is desirably a molded, color coated articlehaving a desired shape, which may be a complex shape, as defined by theshape of mold cavity. Naturally, the mold may include other components,such as slides and lifters which are well known.

The present invention also includes an apparatus for preparing a moldedplastic article, which comprises: a mold cavity; means for holding afilm or blank, desirably a colored film, over the mold cavity; means fordepositing molten plastic onto said film to form a combination of a filmwith molten plastic thereon; and means for forming said film-moltenplastic combination subsequent to depositing molten plastic onto saidfilm in said mold cavity into a molded article having the shape of themold cavity, wherein the film is an outer layer of the molded article.

The present invention adheres to the principle of forming the film inuniformity with the plastic that backs same, and thereby to effect fullshape conformance without optically discernable flaws of the exposedfilm surface, which may be a paint film, and to form the resultantmolded article under closely controlled conditions of temperaturedistribution and pressure in an efficient manner.

Further specific features and advantages of the present invention willappear hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be more readily understood from aconsideration of the following drawings wherein:

FIG. 1 is a partly schematic view of the apparatus and process of thepresent invention in an early stage of the preparation of the moldedarticle;

FIGS. 2 and 3 are partial views showing variations in the process andapparatus of the present invention;

FIG. 4 is a partial view further variation of the process and apparatusof the present invention; and

FIGS. 5, 6, 7 and 8 show additional variations of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to FIGS. 1-3, a mold 10 consisting of cavity half 12 having amold cavity 12a therein and core half 14 is mounted on respectiveplatens 16 and 18. Mold cavity 12a has a shape of the desired finalmolded article. At least one of cavity half and core half isreciprocable in the direction of the arrow 20 from an open to a closedposition and from a closed to open position via motive means (notshown). An extruder/injection unit 22 having a nozzle 24 is arrangedadjacent mold 10 to coact and couple with a hot plastic delivery means,as plate 26. Plate 26 is relatively reciprocable in the direction of thehorizontal arrow 28 from a position adjacent mold cavity 12a to aposition spaced from mold cavity 12a and is supplied with hot, flowableplastic by extruder 22 and nozzle 24. Depending on the nature of plate26, the extruder may be stationary or reciprocable with plate 26.Naturally, other variations in the hot plastic delivery system may beused. For example, the extruder/injection system and hot plasticdelivery means may be stationary externally to the press and the moldtraversed reciprocably relative to the extruder/injection system. Othervariations may be readily contemplated.

Plate 26 in FIG. 1 is a hot runner having an elongated channel 30 whichcommunicates with a multiplicity of openings 32 positioned over moldcavity 12a. Each opening is closeable by known means, as by valve means34. The openings 32 receive hot plastic under pressure from extruder 22through extruder nozzle 24 and hot runner feed channel 30. While theextruder 22 and hot runner delivery plate 26 are coupled, plastic iscaused to flow from nozzle 24 into channel 30. For the delivery plate tooperate when the extruder is detached, a free end 36 of channel 30contains a check valve 38 (shown schematically), and pressurized pistonmeans 40 are added to engage the opposed end 42 of channel 30 to operateby conventional means, for example, a hydraulic cylinder (not shown) toapply force to hot runner channel 30 in the direction of the horizontalarrow 44.

Alternatively, one could selectively close valve means 34 and applypressure through piston means 40, thereby obtaining a thicker coating indesired locations. Alternatively, one could use shooting pots or plasticreservoirs, for example, connected to each individual valve means,thereby obtaining additional resin thickness where desired.

In one method of operation, the extruder 22 is left in place spaced frommold 10 and the plate 26 alone is moved into position over mold cavity12a as shown in FIG. 1, after having been charged with hot plastic byextruder 22. To prevent drooling, check valve 38 is closed. In addition,piston means 40 may be retracted in engagement with channel end 42,thereby creating suction in channel end 42 to better retain the hotplastic therein.

A hold down and spacer frame 46 is aligned with cavity half 12,engageable therewith and detachable therefrom and coupled with means tomove same (not shown) towards and away from cavity half 12 independentlyof the reciprocal movement of core half 14. Thus, a pair of liftcylinders 48 may be mounted on either platens 16 or 18 with mounting onplaten 16 being shown in FIG. 1.

Thus, plate 26 is filled with hot plastic by extruder 22. If the two arecoupled, they are moved so as to place the hot runner into alignmentwith cavity half 12. Before so placing the hot runner, spacer frame 46is lifted away from cavity half 12 far enough to permit a precut film orblank 50 to be placed over the rim 52 (see FIG. 2) of the mold cavity12a of cavity half 12 by any desired means, as for example, shown in the'457 patent. With the blank 50 in place, frame 46 is moved towardscavity half 12 to hermetically clamp blank 50 over the mold cavity 12aas shown in FIG. 2, thereby rendering said cavity capable of retainingelevated fluid pressure. Optionally, the film may be offset from thecavity and supported by air jets. Alternatively, spacer frame 46 mayinclude an upper half 46a and a lower half 46b with a space 47therebetween as shown in FIG. 1. This clamp may be a slip clamp topermit release of the film into mold cavity 12a during forming andthereby minimize edge scrap and reduce the amount of film thinning thatmay occur. If desired, scrap trim may be minimized by folding overexcess film and heat sealing the excess film to inside edge portions ofthe molded article, as by ironing.

Fluid pressure may then be applied to mold cavity 12a under blank 50, asthrough channels 54 connected through a joint manifold 56 with pressurecontrol means 58. The fluid usually used is air, but may also be aninert gas if the material of blank 50 so requires. Alternatively, fluidpressure may be applied through channel 55 in cavity half 12 directlybeneath film blank or film 50 in order to properly hold the film inplace. Preferably, a plurality of locations, or a continuous channel,are provided around the circumference of the film directly beneath thefilm. Also, these may be valved separately from channels 54 or usedinstead of channels 54.

Nozzle valve means 34 are then withdrawn to allow hot plastic to flowfreely from hot runner plate 26 through nozzle openings 32 onto blank 50in the space between the hot runner plate 26 and blank 50 and withinframe 46. The space within frame 46 is not filled under substantialpressure, such as usual in injection molding. Rather, only an accuratelymetered amount 60 of hot plastic is deposited upon blank 50 from hotrunner plate 26, namely that which corresponds substantially to themolding cavity to be formed in mold cavity 12a by cavity half 10 andcore half 14 in the closed condition.

It is important to note that in consequence of introducing the hotplastic into the space within frame 46, no more pressure is appliedunderneath the blank via fluid channels 54 and 55 than that sufficientto support the metered amount 60 of plastic being so deposited.Desirably, the air pressure is variable depending on productrequirements. Indeed, vacuum may be used during forming. Asschematically indicated in FIG. 1, that metered amount 60 will comprisea plastic layer that will conform to the flat surface of the blank onone side, while its opposite surface will have an uneven surface 62 asclearly shown in FIG. 1, showing traces of the viscous flow pattern thatwill have emerged from nozzles 32. Naturally, the nozzles are spacedclosely enough to permit the emerging plastic to form a continuous,homogeneous layer. Alternatively, one polymer could be deposited in adesigned pattern, and a second or a plurality of second polymersdeposited in a designed pattern. This could be done with one or moreextruders feeding for example separate channels to deposit a predesignedpattern of multiple resins. As a further alternative, one couldsequentially feed polymers of different characteristics to providedesigned properties in the finished product.

Each of nozzles 32 may be independently temperature controlled, ifdesired, and hence capable of depositing the plastic in a pattern ofpredetermined temperature distribution.

Before releasing the hot plastic into the space above blank 50, the moldcavity 12a is pressurized as described above, as by air pressureentering through channels 54. Since the finished product is usuallythin, while having a large surface area, the weight of metered plastic60 is relatively low and the average static pressure it exerts upon thefilm or blank 50 is low as well. Hence, relatively low pressure in themold cavity will suffice to keep the blank 50 from sagging under theweight of the metered plastic, even when blank 50 is heated by contactwith the metered plastic. For example, a metered amount of plasticmeasuring 2'×4'×0.5", made of plastic weighing 0.05 pounds per cubicinch, will exert a pressure of 0.025 psi over the said area. Thisamounts to very slight over pressure to support the blank, with theresult that said blank will not bulge (balloon) upward excessively whenpressure is first applied under it. In exceptional instances, the layerof hot plastic being applied over the blank may be of much greaterdepth. Even then, the above indicated pressure would not cause excessivebulging. Forming of a crease-like line at the edge of spacer frame 46,may be prevented as shown by a curved clamping surface 64 thereof inFIG. 2 with slight upward bulging of film 50 shown caused bypressurization of mold cavity 12a. Indeed, upward bulging may bedesirable in some instances, as for feed draw parts.

After deposition of the plastic layer 60 on film 50, plate 26 is movedfrom between cavity half 12 and core half 14 and mold 10 is closed, asby moving core half 14 into mold cavity 12a. This results in forming thefilm and deposited plastic into a composite laminate in the shape of theclosed mold cavity in an expeditious and convenient manner.

The blank is preferably plastic, and any desired plastic material may beused for the blank or molten plastic material, for example, polyolefins,polyvinyl chloride, polystyrene, polycarbonates, etc. Any thermoplasticand/or thermoset material may be used for the molten material, such asfor example, structural foam, rim, epoxy, polyurethanes, bulk moldingcompound, sheet molding compound, etc. The blank may be cut or stampedfrom a web and a supply of blanks having the size and shape to fit overmold cavity 12a maintained adjacent mold 10 for transfer to the mold asdescribed above. The depth of color on the blank may naturally be varieddepending on needs. One should naturally consider the thinning of theblank or film during processing and adjust the color depth to the amountof deformation any given portion of the blank or film is to undergo.Thus, for example, thicker paint coatings may be applied to selectiveblank or film locations that are to obtain greater deformation duringprocessing in order to obtain uniformity of color in the final moldedproduct. The blank or film may, for example, be intaglio-embossed. Theblank may be applied to the mold with robot means or removably adheredto a carrier film strip. The carrier film strip may be provided withmeans to register the position of the blanks relative to the mold halfonto which the blanks are to be placed, e.g., edge perforations. Thecarrier, with the blanks attached, may then be supplied from a roll.Once the blank and mold are juxtaposed, suction is applied to the edgeof the blank by the mold, as through channels, sufficient to separatethe blank from the carrier strip. Naturally, other transfer means mayreadily be used.

FIG. 3 shows an alternate method for applying the hot plastic. Insteadof plate 26 being a hot runner as shown in FIG. 1, the extruder 22 iscoupled with a so-called coat hanger die 70, serving as a hot plasticdelivery plate, i.e., die with a slit opening 72 for the plastic asnormally used for the extrusion of wide sheets. The extruder 22 and die70 are reciprocable in the direction of arrow 74 towards and away frommold 10. In operation, the blank 50 having been placed over the moldcavity 12a and clamped down as by spacer frame 46, as in FIGS. 1-2, theextruder 22 and die 70 are traversed over blank 50, and the desiredlayer of hot plastic is deposited thereover. The thickness of theplastic layer is given by the speed of traverse, the output of theextruder and the dimensions of the die, all controlled in a conventionalmanner. At the end of the traverse, the extruder is shut off andreturned to its starting position. One may provide an extruder withwidth and/or thickness control to control the thickness and/or width ofthe plastic layer. The speed of traverse and/or the output of theextruder could be variable. The positioning of the extruder in the X, Yand Z planes could be variable to vary the dimensions and/orconfiguration of the plastic layer.

The advantage of this procedure is in its lower tooling cost. However,it may only be used when progressive deposition, as againstsimultaneous, with a hot runner, is acceptable, e.g., for narrow partsrequiring but a relatively short traverse of the extruder.

A significant feature of the present invention is the uniformity ofheating of the film or blank without having to resort to external means,and the assurance that the forming operation is carried outsimultaneously, film or blank and the backing layer, followed by theapplication of high enough molding pressures to provide mold conformanceof both. The finish of the film is thereby preserved and opticallydetectable imperfections are avoided. Also, this procedure requires muchlower clamping pressure than conventional procedures.

While the foregoing procedure is aimed primarily at application in theexterior of vehicles, it should be noted that there are many other typesof components that would benefit from the subject process of compressionmolding with a colored finish and with an accurately molded article,particularly for large household appliances and architecturalcomponents.

Referring to the variation of FIG. 4, platen 80 is shown with anelastomeric forming mandrel 82 therein containing air slots 84 andpressure control means 86 connected thereto. Mold 88 is shown with moldcavity 90 therein, film 92 and clamping frame 94 to hold the film on themold rim 96. The hot plastic 98 is deposited on film 92 as in previousembodiments. As shown in the embodiment of FIG. 4, slots 84 intersect amanifold slot 100 which is connected to a source of fluid pressure, asair.

In operation, the elastomeric mandrel 82 enters the clamping frame 94.Pressure air is applied to slots 84 expanding the slots into passages.Thereby, pressure is applied to the deposited plastic 98 and the film92. Pressure is present in the mold cavity 90 as in FIGS. 1-3 and thepressure is controllably released at the same time, resulting in blowmolding of plastic 98 and film 92. The mandrel 82 moves simultaneouslydownward in the direction of arrow 102. As the plastic and film reachthe mold surface, the mandrel continues and due to its elastic natureconforms to the surface of the plastic away from the film, andcontinuing pressure by the platen exerts hydrostatic pressure on theplastic. That pressure may be much higher than would be economicallyavailable from a compressed fluid, e.g., over 1000 psi. The top or innersurface of the finished part will be substantially parallel to the moldsurface. The mandrel is preferably cooled, as is the mold.

The foregoing process represents an improved method and apparatus forforming large, panel-like, thick parts because it overcomes thedifficulty of heating a thick plate uniformly. It is useful, whether acolored or painted film is required or not. Any plastic film may be usedas a support of the hot plastic so long as it is compatible with theplastic to be molded. The compatibility may be achieved by a variety ofmethods, such as melt bonding, use of adhesives or tie layers.Alternatively, in some cases one could use a non-compatible or removablefilm layer.

Alternatively, one may employ a second film layer 93 (see FIG. 4) underthe main film layer 92 to provide further support for the main filmlayer 92. For example, a second film layer may be secured over the moldcavity to support a thinner, fragile film or multiple films in position,or to support a logo or decal 93' on film 92. Naturally, the second filmmay desirably be transparent, and naturally also the second film may beused with any embodiments of the present invention. The second film willdesirably be secured to the mold in the same manner as the main film.

FIGS. 5, 6 and 7 show detailed variations of the present invention.

As shown in FIG. 5, film 110 is held over mold cavity half 112 by frame114 and molten plastic deposited thereon by manifold 116 via outlets 118in the direction of arrows 120. Mold cavity half 112 includes coolingchannels 122 and compressed air or vacuum channels 124 to provide airpressure under film 110 or to aid in the forming procedure. Thetemperature of the film sheet is adjusted according to the extent ofdeformation it is to undergo. The film-molten plastic combination iscompression molded in the mold cavity half after removal of manifold 116from between the mold halves via core half 126 which contains coolingchannels 128. The finished molded article including the film anddeposited plastic is then formed between the mold cavity and mold core.

FIG. 6 is similar to FIG. 5, with the use of traversing extruder 130which extrudes a molten plastic layer 132 onto film 110. Air coolingnozzles 134 may be provided to properly temperature condition the moltenplastic layer 132. Both the extruder 130 and cooling nozzles 134 aremovable from a position above film 110 as shown in FIG. 6 to a positionspaced from film 110 to permit engagement of core half 126 with thefilm-molten plastic combination.

FIG. 7 shows film inserter 140 and film feed means 142 for feeding afilm 144 to mold 146 above mold cavity half 148. Reciprocable hotplastic delivery means 150 movable in the direction of arrow 152 isprovided adjacent mold 146 to prepare a molded product 154 as inprevious embodiments. In the embodiment of FIG. 7, a metal or plasticinsert 156 may be fed to the mold to be made a part of molded product154 as shown. Alternatively, a fiberglass mat or scrim may be used as areinforcement, or any suitable and desired reinforcing or functionalmaterial, as random fiberglass material, textiles, metal, plastic, etc.One may reinforce the entire structure or selectively stiffen thestructure as required. Product removal robot 158 is provided adjacentmold 146 to remove the molded product. The molded product, of course,may have a variety of uses, as for example, a side panel 160 for anautomobile 162.

FIG. 8 shows a closed mold 170 with cavity portion 172 and core portion174. The molded article includes film layer 176, plastic layer 178 andreinforcement material or fasteners 180. The reinforcement material orfasteners 180 may be applied to core portion 174 in order to provideexact location on the molded article. When the mold 170 is closed, thefastener or the like may be ejected via ejection passage 182 or anyother desired means to become firmly bonded to or embedded in theplastic layer. Ejection may for example be by hydraulic or mechanicalmeans. The reinforcements or fasteners may be selectively placed on themolded article as shown in FIG. 8, or may completely cover the moldedarticle.

Alternatively, the assembly of the frame, film, plastic layer assemblymay be prepared at an upstream location spaced from the mold, forexample, on a removable board. All pre-conditioning operations can thenbe done before the assembly is deposited on the mold and the only stepperformed by the mold is the final forming operation. This will resultin an assembly line type operation with the assembled andpre-conditioned film-plastic held on a frame transferred to the mold forfinal forming.

As a further alternative, one can use co-extrusion for the moltenplastic. Plastic from a die may be extruded in co-layers or in multiplepasses from two heads to deposit different polymers and/or compositionsand/or fillers.

As a still further alternative, one may employ a variety of types offilms, as a conductive film (EMI-RFI), a film with UV and/or infraredabsorption characteristics, or any desired and convenient film withdesired range of properties to achieve particular results.

Thus, in accordance with the present invention, a die cut film blank isplaced over the mold cavity. It is cut to match the cavity edge withjust enough overlap to permit clamping. The structural plastic isapplied over the blank while the cavity under it is pressurized enoughto support the weight of the plastic. It is dispensed either from a hotrunner or a modified hot runner or from a traversing extruder. It isthen conditioned as by cooling nozzles to acquire a point-by-pointpreset temperature distribution, including the film or blank. The moldis closed by a mold core, while the pressure in the cavity is releasedand the cavity is evacuated. The molded article may be provided withinserted elements of a structure made of metal or different plasticsincluding for example scrim, fibers, woven and non-woven mats, etc. Thecore compresses the plastic which is coated on the core side of thefilm. If a paint film is used, the part can obtain a Class A finish, asmolded. Because of the controlled deformation parameters or depth ofcolor, the deformed film thickness can maintain uniform gloss and depthof color after molding. To finish the process, the part is cooled in themold, which is temperature controlled. No mechanical ejectors are neededand no ejector marks are left: upon opening the mold, the part isseparated from the mold surface by any desired means, as byair-ejectors, using the channels that were used at the outset to "float"the carrier film, and transferred by suction to the robot end of arm.

Unlike injection molding, this procedure is based on the followingconsiderations. In the injection molding process, molten plastic isforced through a small orifice into a large space confined by walls thatare intensively chilled. Mold filling occurs by coating the mold wallsand filling the diminishing space between them progressively, underconditions of laminar flow. This phenomenon, called tunnel-flow, makescoinjection possible. The molten and then gradually solidifying plasticcools inward from the mold wall, through the first coat and theadjoining laminar structure, in a material that is a poor heatconductor. The rate and amount of shrinkage from melt to solid variesaccordingly layer-by-layer, and depends on the changes in wall thicknessspot-by-spot. Passing through the melt-transition temperature, T_(M),particularly in crystalline plastics, interferes severely with theconformance of the plastic to the mold. Hence, the sink-marks oppositethe gate vestige and at the opposite of a thick rib, and waviness oflarger surfaces. Another fatal consequence of volume change at T_(M) inlarge, thin injection molded panels of varying curvature, can be theresidual stresses that warp surfaces as they are relieved, e.g., byenvironment exposure, as temperature rises, or corrosive moisture isabsorbed; this, in addition to other expected consequence of stressconcentrations.

The solution of this nearly intractable problem is to bypass the T_(M)--caused volume change in the molding process. This is precisely whatthe compression molding of the present invention accomplishes.

As an alternative embodiment, one may provide a plastic film, coveredwith molten plastic as above, covered in turn with a reinforcementmaterial. The male mold would press the components together and embedthe reinforcement material in the plastic. Alternatively, one mayprovide an additional layer of molten plastic material over thereinforcement material, effectively embedding the reinforcement materialbetween the two plastic layers.

The present invention achieves significant advantages over injectionmolding procedures. Thus, the present invention results in lowerequipment and tooling investments. Additionally, the use of paint filmsto produce finished structural panels eliminates the need for costlypaint plant investments, and eliminates all the environmental issuesrelated to painting since the film can be made in a closed,environmentally secure chamber.

In addition, no preforming of the film is required to produce Class Astructural components. Cycle times are faster than injection molding.Forming pressures are lower than conventional injection molding.Further, the open mold nature of the subject process and apparatuspermits selective insertion of reinforcements or additional components,such as fasteners, logos, indicias, designs, or the like.

It is to be understood that the invention is not limited to theillustrations described and shown herein, which are deemed to be merelyillustrative of the best modes of carrying out the invention, and whichare susceptible of modification of form, size, arrangement of parts anddetails of operation. The invention rather is intended to encompass allsuch modifications which are within its spirit and scope as defined bythe claims.

What is claimed is:
 1. Process for preparing a molded article which comprises:providing a mold with an open mold cavity having a mold surface defining a mold cavity shape; clamping a film over said open mold cavity and supporting said film in a position spaced from said mold surface; providing molten plastic delivery means above said film and depositing a metered amount of molten plastic onto said film, while supported, from said delivery means in a plurality of delivery locations along a facing surface of said film to deliver the molten plastic in a layer across said facing surface of said film to form a combination of a film with the layer of molten plastic thereon; removing said deliverv means; and subsequently forming said combination in said mold cavity against said mold surface to form a molded article having the shape of said mold cavity, wherein said film is an outer layer of the molded article.
 2. Process according to claim 1, wherein said combination is formed in said mold cavity at least in part by a mold core which compresses said combination and forms said combination into the shape of said mold cavity.
 3. Process according to claim 2, wherein said mold core is an elastomeric forming mandrel.
 4. Process according to claim 2, wherein said mold core and mold cavity are vertically oriented.
 5. Process according to claim 2, wherein said molten plastic delivery means is positioned adjacent said film between the mold cavity and mold core for delivering molten plastic onto said film.
 6. Process according to claim 5, wherein said molten plastic delivery means is relatively reciprocable from a position adjacent said film for delivery of molten plastic onto said film to a position spaced from said film.
 7. Process according to claim 5, wherein the facing surface of said film is flat, and wherein said molten plastic is delivered onto said film so that said molten plastic forms a continuous homogeneous plastic layer with a surface which conforms to the flat facing surface of said film and with an opposite exposed uneven surface of said plastic layer.
 8. Process according to claim 5, including the step of temperature conditioning the molten plastic after said molten plastic is deposited onto said film and before said subsequent forming step.
 9. Process according to claim 1, including a second, supporting film on said film between said film and the mold cavity.
 10. Process according to claim 9, including providing an insert between said film and said second film.
 11. Process according to claim 10, including the step of providing a transparent second film so that the insert can be seen through the second film.
 12. Process according to claim 1, including the step of including an insert of a dissimilar material bonded to said molded article.
 13. Process according to claim 12, including the step of embedding said insert in said molded plastic.
 14. Process according to claim 12, wherein said insert is selected from the group consisting of metal, plastic, fiberglass and textile.
 15. Process according to claim 12, wherein said molten plastic forms an inner layer of said molded article, with a first surface thereof bonded to said film and a second surface thereof opposed to said first surface, including the step of bonding said insert to the second surface.
 16. Process according to claim 1, including the step of holding said film over the mold cavity in a channel of a frame member.
 17. Process according to claim 16, including the step of releasing said film from said channel during forming to minimize edge scrap and reduce localized thinning of the film.
 18. Process according to claim 1, wherein said film is held over said mold cavity by air pressure.
 19. Process according to claim 18, wherein the air pressure is variable.
 20. Process according to claim 1, wherein said film is colored.
 21. Process according to claim 1, including the step of delivering said molten plastic onto said film from a hot runner having a plurality of molten plastic outlets positioned adjacent said film.
 22. Process according to claim 1, wherein said combination is formed at least in part by fluid pressure.
 23. Process according to claim 1, wherein said combination is formed at least in part by a mandrel.
 24. Process according to claim 1, including the step of depositing differential thicknesses of molten plastic on said film.
 25. Process according to claim 1, including the step of holding said film over the mold cavity in a frame member, and providing at least one of suction and air flow directly beneath said film through said frame member.
 26. Process according to claim 1, including depositing multiple plastic materials on said film.
 27. Process according to claim 1, wherein said film is selected from the group consisting of a conductive film, a film with UV absorption characteristics, and a film with infrared absorption characteristics.
 28. Process for preparing a molded article which comprises:providing a mold with an open mold cavity having a mold surface defining a mold cavity shape; clamping a film over said open mold cavity and supporting said film in a position spaced from said mold surface; providing molten plastic delivery means above said film and depositing a metered amount of molten plastic onto said film, while supported, from said delivery means while said delivery means traverses said film to deliver the molten plastic in a layer across a facing surface of said film to form a combination of a film with the layer of molten plastic thereon; removing said delivery means; and subsequently forming said combination in said mold cavity against said mold surface to form a molded article having the shape of said mold cavity, wherein said film is an outer layer of the molded article.
 29. Process according to claim 28, wherein said combination is formed in said mold cavity at least in part by a mold core which compresses said combination and forms said combination into the shape of said mold cavity.
 30. Process according to claim 29, wherein said mold core is an elastomeric forming mandrel.
 31. Process according to claim 29, wherein said mold core and mold cavity are vertically oriented.
 32. Process according to claim 29, wherein said molten plastic delivery means is positioned adjacent said film between the mold cavity and mold core for delivering molten plastic onto said film.
 33. Process according to claim 32, wherein said molten plastic delivery means is relatively reciprocable from a position adjacent said film for delivery of molten plastic onto said film to a position spaced from said film.
 34. Process according to claim 32, wherein the facing surface of said film is flat, and wherein said molten plastic is delivered onto said film so that said molten plastic forms a continuous homogeneous plastic layer with a surface which conforms to the flat facing surface of said film and with an opposite exposed uneven surface of said plastic layer.
 35. Process according to claim 32, including the step of temperature conditioning the molten plastic after said molten plastic is deposited onto said film and before said subsequent forming step.
 36. Process according to claim 28, including a second, supporting film on said film between said film and the mold cavity.
 37. Process according to claim 36, including providing an insert between said film and said second film.
 38. Process according to claim 37, including the step of providing a transparent second film so that the insert can be seen through the second film.
 39. Process according to claim 28, including the step of including an insert of a dissimilar material bonded to said molded article.
 40. Process according to claim 39, including the step of embedding said insert in said molded plastic.
 41. Process according to claim 39, wherein said insert is selected from the group consisting of metal, plastic, fiberglass and textile.
 42. Process according to claim 39, wherein said molten plastic forms an inner layer of said molded article, with a first surface thereof bonded to said film and a second surface thereof opposed to said first surface, including the step of bonding said insert to the second surface.
 43. Process according to claim 28, including the step of holding said film over the mold cavity in a channel of a frame member.
 44. Process according to claim 43, including the step of releasing said film from said channel during forming to minimize edge scrap and reduce localized thinning of the film.
 45. Process according to claim 28, wherein said film is held over said mold cavity by air pressure.
 46. Process according to claim 45, wherein the air pressure is variable.
 47. Process according to claim 28, wherein said film is colored.
 48. Process according to claim 28, including the step of delivering said molten plastic onto said film from a hot runner having a plurality of molten plastic outlets positioned adjacent said film.
 49. Process according to claim 28, wherein said combination is formed at least in part by fluid pressure.
 50. Process according to claim 28, wherein said combination is formed at least in part by a mandrel.
 51. Process according to claim 28, including the step of depositing differential thicknesses of molten plastic on said film.
 52. Process according to claim 28, including the step of holding said film over the mold cavity in a frame member, and providing at least one of suction and air flow directly beneath said film through said frame member.
 53. Process according to claim 28, including depositing multiple plastic materials on said film.
 54. Process according to claim 28, wherein said film is selected from the group consisting of a conductive film, a film with UV absorption characteristics, and a film with infrared absorption characteristics. 